Modular wall component and a method for manufacturing a modular wall component

ABSTRACT

A modular wall component is provided. One aspect of the modular wall component includes at least two vertical panels; at least two horizontal panels configured to form a lattice frame together with the at least two vertical panels, wherein each of the at least two horizontal panels is connected to each of the at least two vertical panels by an interior joint, respectively; and a feature configured to secure a mechanical component, an electrical component, or a plumbing component.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims priority under 35 U.S.C. § 119 to U.S.Provisional Application No. 63/346,010, filed on May 26, 2022, in theUnited States Patent and Trademark Office, the disclosure of which isincorporated by reference herein in its entirety.

BACKGROUND

A residential home, such as a townhome, apartment, condominium,accessory dwelling unit, or single-family home (SFH), includes a complexnetwork of building components. Examples of building components includea mechanical system, an electrical system, a plumbing system, and datainfrastructure. Such systems provide basic conveniences found in a cleanand comfortable home environment.

Mechanical, electrical, and plumbing (MEP) components and datainfrastructure components are vital elements of many modern buildings.For instance, mechanical components may include heating and cooling (ortemperature control) components, electrical components may includelights, outlets, appliances, etc., and plumbing components may includewater lines, toilets, sinks, hook-ups, etc. In some cases, MEPcomponents may be shipped and installed individually on-site during aconstruction process of a building. In some cases, MEP components may beinstalled in a building by different contractors at different times(e.g., with little to no communication on how the MEP components relateto one another).

In some cases, when one or more contractors build a home, thecontractors might not consider tolerancing or constraints for secondaryprocesses (e.g., as secondary processes may have been customized due tobuild tolerances). Timing and coordination of contractors to install theMEP components produce inherent inefficiencies. As a result, such buildsmay be ineffective, as there may be an excessive waste of material,contractor/build time, costs, etc. For example, extra furred-out wallsmay be required to address coordination deficiencies, resulting inreduced space and poor workflow. These costs are then passed to thehomeowner or home buyer, contributing to already-excessive homeaffordability. There is therefore a need in the art for a modular wallcomponent that increases the ease and efficiency of installing an MEPcomponent in a building.

SUMMARY

A modular wall component is described. One or more aspects of themodular wall component include at least two vertical panels; at leasttwo horizontal panels configured to form a lattice frame together withthe at least two vertical panels, wherein each of the at least twohorizontal panels is connected to each of the at least two verticalpanels by an interior joint, respectively; and a feature configured tosecure a mechanical component, an electrical component, or a plumbingcomponent.

A modular wall component is described. One or more aspects of themodular wall component include at least two vertical panels; at leasttwo horizontal panels configured to form a lattice frame together withthe at least two vertical panels, wherein each of the at least twohorizontal panels forms an edge of a plurality of internal rectangularspaces defined by the at least two vertical panels; and a featureconfigured to secure a mechanical component, an electrical component, ora plumbing component.

A method for manufacturing a modular wall component is described. One ormore aspects of the method, apparatus, non-transitory computer readablemedium, and system include providing at least two vertical panels;providing at least two horizontal panels; cutting at least two interiorjoints in each of the at least two vertical panels and each of the atleast two horizontal panels; cutting a feature from the at least twovertical panels or the at least two horizontal panels; and connectingthe at least two vertical panels and the at least two horizontal panelsusing the at least two interior joints in each of the at least twovertical panels and the at least two horizontal panels to form themodular wall component.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows an example of a modular wall component according to aspectsof the present disclosure.

FIG. 2 shows an example of a modular wall component including plumbingcomponents according to aspects of the present disclosure.

FIG. 3 shows an example of a back view of the modular wall component ofFIG. 2 according to aspects of the present disclosure.

FIG. 4 shows an example of a side view of the modular wall component ofFIG. 2 according to aspects of the present disclosure.

FIG. 5 shows an example of a horizontal perspective cross-sectional viewof the modular wall component of FIG. 2 according to aspects of thepresent disclosure.

FIG. 6 shows an example of a vertical cross-sectional view of themodular wall component of FIG. 2 according to aspects of the presentdisclosure.

FIG. 7 shows an example of a vertical perspective cross-sectional viewof the modular wall component of FIG. 2 according to aspects of thepresent disclosure.

FIGS. 8 through 9 show examples of perspective detail views of themodular wall component of FIG. 2 according to aspects of the presentdisclosure.

FIG. 10 shows an example of a front detail view of the modular wallcomponent of FIG. 2 according to aspects of the present disclosure.

FIG. 11 shows an example of a modular wall component installationaccording to aspects of the present disclosure.

FIGS. 12 through 15 show an example of installing a modular wallcomponent according to aspects of the present disclosure.

FIG. 16 shows an example of a method for providing a modular wallcomponent according to aspects of the present disclosure.

FIG. 17 shows an example of a method for providing a modular wallcomponent including a second lattice frame according to aspects of thepresent disclosure.

DETAILED DESCRIPTION

Mechanical, electrical, and plumbing (MEP) components and datainfrastructure components are vital elements of many modern buildings.For instance, mechanical components may include heating and cooling (ortemperature control) components, electrical components may includelights, outlets, appliances, etc., and plumbing components may includewater lines, toilets, sinks, hook-ups, etc. In some cases, MEPcomponents may be shipped and installed individually on-site during aconstruction process of a building. In some cases, MEP components may beinstalled in a building by different contractors at different times(e.g., with little to no communication on how the MEP components relateto one another).

In some cases, when one or more contractors build a home, thecontractors might not consider tolerancing or constraints for secondaryprocesses (e.g., as secondary processes may be customized due to buildtolerances). As a result, such builds may be inefficient, as there maybe an excessive waste of material, contractor/build time, costs, etc.For example, extra furred-out walls may be required to addresscoordination deficiencies, resulting in reduced space and poor workflow.As such, it may be desirable to design and manufacture anoff-site-constructed modular unit that can be used in different-sizedhouses and in different locations.

According to some aspects, a modular wall component as described hereinincludes a lattice frame comprising interfacing panels to promotestrength and ease of manufacturing. In some cases, the interfacingpanels are cut from a wooden flat sheet stock, providing athree-dimensional structure in the general form of a lattice frame. Insome cases, the modular wall component includes pre-located andpre-engineered mounting points for a mechanical component, an electricalcomponent, a plumbing component, or a combination thereof. In somecases, the modular wall component includes the mechanical component, anelectrical component, and/or a plumbing component. For example, amechanical component may include a supply fan, an exhaust fan, an HVACcontrol system, condensation piping, ducting, a temperature sensor, ahumidity sensor, a communication box, and the like. An electricalcomponent may include an outlet, a light switch, solar conduit, a waterheater whip, and the like. A plumbing component may include a toilet,hot/cold water supply, a valve, a shower temperature control, a drainline, a trap primer, an escutcheon, and the like.

In some cases, the modularity of the modular wall component provides foreasy installation of the modular wall component and provides for otherstructures at the installation site to be considered and accounted forwhen designing and manufacturing the modular wall component. Bycontrast, during a traditional building process, a plumber, anelectrician, an HVAC technician, a finisher, etc., may individuallyplace each MEP component without a pre-existing structure to coordinatethe installation of the MEP components, thereby risking damage andcross-contamination of componentry, etc. According to some aspects, themodular wall component provides a “plug-in” system that promotes an easyinstallation of one or more MEP components in the modular wall componentaccording to predetermined locations.

In some cases, the modular wall component may provide an attachmentsystem for an external component, such as a sink, a shower, a cabinet,etc. The modular wall component may be a plug-and-play system, such thaton-site installation is minimally invasive and repeatable, and mayinclude components such as plumbing components, electrical components,heating components, valves, switches, and the like. In some cases, themodular wall component can include a fire detection system, a fireprotection system (e.g., such as sprinklers, water delivery systems,etc.), or a combination thereof.

In some cases, the modular wall component accounts for alignment onservices like plumbing component slope indexing. In some cases, themodular wall component accounts for an affordance for a verticalmovement of service sub-assemblies from an indexing point of a plumbingcomponent to accommodate field connections to the plumbing component. Insome cases, the modular wall component accounts for an affordance for anaddition of structural reinforcement for load attachment points of themodular wall component. In some cases, the modular wall componentprovides for a field tolerance for connecting the modular wall componentto a floor, a ceiling, a wall, or a combination thereof to beaccommodated. In some cases, the modular wall component includes one ormore features that provides for a “drop-in” of preconstructed MEP systemsub-assemblies instead of a “fish-through” method of standardconstruction techniques.

Modular Wall Component

FIG. 1 shows an example of a modular wall component 100 according toaspects of the present disclosure. Modular wall component 100 is anexample of, or includes aspects of, the corresponding element describedwith reference to FIGS. 2-15 .

In one aspect, modular wall component 100 includes first lattice frame101, second lattice frame 112, split 123, a plurality of features 124,first mounting panel 125 a, second mounting panel 125 b, third mountingpanel 125 c, fourth mounting panel 125 d, fifth mounting panel 125 e,first mounting panel joint 126 a, second mounting panel joint 126 b,third mounting panel joint 126 c, fourth mounting panel joint 126 d,first buttress 127, and buttress joint 128.

First lattice frame 101 is an example of, or includes aspects of, thecorresponding element described with reference to FIG. 4 . In oneaspect, first lattice frame 101 includes first vertical panel 102 a,second vertical panel 102 b, third vertical panel 102 c, fourth verticalpanel 102 d, first horizontal panel 105 a, second horizontal panel 105b, third horizontal panel 105 c, fourth horizontal panel 105 d, firstinterior joint 108 a, second interior joint 108 b, third interior joint108 c, fourth interior joint 108 d, fifth interior joint 109 a, sixthinterior joint 109 b, seventh interior joint 109 c, eighth interiorjoint 109 d, ninth interior joint 110, first internal rectangular space111 a, and second internal rectangular space 111 b.

First vertical panel 102 a is an example of, or includes aspects of, thecorresponding element described with reference to FIGS. 3 and 5 . Secondvertical panel 102 b is an example of, or includes aspects of, thecorresponding element described with reference to FIGS. 6 and 7 . Thirdvertical panel 102 c is an example of, or includes aspects of, thecorresponding element described with reference to FIGS. 4, 6, and 7 . Inone aspect, first vertical panel 102 a includes vertical interior face103 and vertical exterior face 104.

As shown in FIG. 1 , each of first vertical panel 102 a, second verticalpanel 102 b, third vertical panel 102 c, and fourth vertical panel 102 dis an example of a vertical panel included in a set of vertical panelsincluded in first lattice frame 101. As shown in FIG. 1 , first latticeframe 101 includes seven vertical panels. However, embodiments of thepresent disclosure are not limited thereto, and a lattice frameaccording to the present disclosure may include one or more verticalpanels.

According to some aspects, a vertical panel extends in a first direction(e.g., a y-direction). In some cases, a vertical interior face (such asvertical interior face 103) of a vertical panel faces a second directioncrossing the first direction (e.g., an x-direction). In some cases, thesecond direction is orthogonal to the first direction. In some cases, avertical exterior face (such as vertical exterior face 104) of avertical panel faces a third direction crossing the first direction andthe second direction (e.g., a z-direction). In some cases, the thirddirection is orthogonal to the first direction and to the seconddirection.

In some cases, a vertical interior face of a vertical panel (e.g., firstvertical panel 102 a) faces another vertical interior face of anothervertical panel (e.g., second vertical panel 102 b). In some cases, avertical exterior face (e.g., vertical exterior face 104) of a verticalpanel faces outwardly from modular wall component 100 in the thirddirection.

According to some aspects, a vertical panel comprises a wood. Accordingto some aspects, a vertical panel comprises at least one of a wood, awood composite, a plastic, a metal, or a masonry material (including,e.g., concrete or brick).

First horizontal panel 105 a is an example of, or includes aspects of,the corresponding element described with reference to FIGS. 3-4 and 6-7. Second horizontal panel 105 b is an example of, or includes aspectsof, the corresponding element described with reference to FIGS. 4 and 5. Third horizontal panel 105 c is an example of, or includes aspects of,the corresponding element described with reference to FIGS. 4 and 7 .Fourth horizontal panel 105 d is an example of, or includes aspects of,the corresponding element described with reference to FIGS. 4 and 5 . Inone aspect, first horizontal panel 105 a includes horizontal interiorface 106 and horizontal exterior face 107.

As shown in FIG. 1 , each of first horizontal panel 105 a, secondhorizontal panel 105 b, third horizontal panel 105 c, and fourthhorizontal panel 105 d is an example of a horizontal panel of a set ofhorizontal panels included in first lattice frame 101. As shown in FIG.1 , first lattice frame 101 includes five horizontal panels. However,embodiments of the present disclosure are not limited thereto, and alattice frame according to the present disclosure may include one ormore horizontal panels.

According to some aspects, a horizontal panel extends in the seconddirection. In some cases, a horizontal interior face (such as horizontalinterior face 106) of a horizontal panel faces the first direction. Insome cases, a horizontal exterior face (such as horizontal exterior face107) of a horizontal panel faces the third direction.

In some cases, a horizontal interior face of a horizontal panel (e.g.,first horizontal panel 105 a) faces another horizontal interior face ofanother horizontal panel (e.g., second horizontal panel 105 b). In somecases, a horizontal exterior face (e.g., horizontal exterior face 107)of a horizontal panel faces outwardly from modular wall component 100 inthe third direction.

According to some aspects, a horizontal panel comprises a wood.According to some aspects, a horizontal panel comprises at least one ofa wood, a wood composite, a plastic, a metal, or a masonry material(including, e.g., concrete or brick).

First interior joint 108 a is an example of, or includes aspects of, thecorresponding element described with reference to FIG. 3 . Secondinterior joint 108 b is an example of, or includes aspects of, thecorresponding element described with reference to FIGS. 6 and 7 . Thirdinterior joint 108 c and sixth interior joint 109 b are examples of, orinclude aspects of, the corresponding elements described with referenceto FIG. 5 . Seventh interior joint 109 c is an example of, or includesaspects of, the corresponding element described with reference to FIGS.4 and 6-7 . Eighth interior joint 109 d is an example of, or includesaspects of, the corresponding element described with reference to FIGS.4 and 7 . Ninth interior joint 110 is an example of, or includes aspectsof, the corresponding element described with reference to FIG. 4 .

In some aspects, at least two horizontal panels (e.g., first horizontalpanel 105 a and second horizontal panel 105 b) are configured to formthe first lattice frame 101 together with at least two vertical panels(e.g., first vertical panel 102 a and second vertical panel 102 b),where each of the at least two horizontal panels is connected to each ofthe at least two vertical panels by an interior joint (e.g., firstinterior joint 108 a, second interior joint 108 b, third interior joint108 c, and fourth interior joint 108 d), respectively. In some aspects,an interior joint includes a slot joint.

For example, in some cases, a vertical panel (such as first verticalpanel 102 a) extends such that the vertical panel contacts at least twohorizontal panels (e.g., first horizontal panel 105 a and secondhorizontal panel 105 b). Likewise, in some cases, a horizontal panel(such as first horizontal panel 105 a) extends such that the horizontalpanel contacts at least two vertical panels (e.g., first vertical panel102 a and second vertical panel 102 b). In some cases, at each point ofcontact between a vertical panel and a horizontal panel, the verticalpanel and the horizontal panel form an interior joint.

In some cases, an “interior joint” (such as first interior joint 108 a,second interior joint 108 b, third interior joint 108 c, fourth interiorjoint 108 d, fifth interior joint 109 a, sixth interior joint 109 b,seventh interior joint 109 c, eighth interior joint 109 d, or ninthinterior joint 110) refers to a joint that may be formed by two or morepanels such that an interior face of a first panel is adjacent to andforms an angle (such as a right angle) with an interior face of a secondpanel. In an example, as shown in FIG. 1 , first interior joint 108 a isformed by first vertical panel 102 a and first horizontal panel 105 asuch that vertical interior face 103 is disposed adjacent to and formsan angle with a horizontal interior face of first horizontal panel 105a.

In some cases, each of first interior joint 108 a, second interior joint108 b, third interior joint 108 c, fourth interior joint 108 d, fifthinterior joint 109 a, sixth interior joint 109 b, seventh interior joint109 c, eighth interior joint 109 d, and ninth interior joint 110 is aslot joint. In some cases, a “slot joint” refers to a joint that may beformed by inserting a slotted portion of a first panel into a slottedportion of at least a second panel. For example, as shown in FIG. 1 ,first interior joint 108 a is formed as a slot joint by inserting a slotdisposed in first vertical panel 102 a into a slot disposed in firsthorizontal panel 105 a, such that at least a portion of first verticalpanel 102 a at least partially surrounds at least a portion of firsthorizontal panel 105 a, and at least a portion of first horizontal panel105 a at least partially surrounds at least a portion of first verticalpanel 102 a.

In some cases, a slot joint comprises a middle joint (such as fifthinterior joint 109 a). In some cases, a “middle joint” refers to a jointthat may be formed by at least two panels, where at least one tab of thefirst panel (e.g., a portion of the first panel that extends from anedge of the first panel) is respectively inserted into at least one slotof at least the second panel, such that the at least one tab is at leastpartially enclosed (e.g., on four sides) by the second panel. Forexample, as shown in FIG. 1 , fifth interior joint 109 a (indicated bydashed lines) is formed as a middle joint by inserting a tab of firsthorizontal panel 105 a that extends in the second direction from an edgeof first horizontal panel 105 a into a slot disposed in fourth verticalpanel 102 d, and sixth interior joint 109 b (indicated by dashed lines)is formed by inserting a tab of first vertical panel 102 a that extendsin the first direction from an edge of first vertical panel 102 a into aslot disposed in fourth horizontal panel 105 d.

In some cases, a slot joint comprises an end joint (such as ninthinterior joint 110). In some cases, an “end joint” refers to a jointthat may be formed by at least two panels, where at least one tab of thefirst panel (e.g., a portion of the first panel that extends from anedge of the first panel) is respectively inserted into at least one slotof at least the second panel, where the slot is disposed at an edge ofthe second panel, such that the at least one tab is at least partiallyenclosed (e.g., on at least three sides) by the second panel. Fromanother structurally equivalent perspective, in some cases, an end jointmay be formed by inserting a tab extending from the first panel betweena pair of tabs extending from the second panel. For example, as shown inFIG. 1 , ninth interior joint 110 (indicated by dashed lines) is formedby inserting a tab of third vertical panel 102 c that extends in thefirst direction from an edge of third vertical panel 102 c into a slotdisposed at an edge of fourth horizontal panel 105 d, or by inserting atab of fourth horizontal panel 105 d that extends in the seconddirection from an edge of fourth horizontal panel 105 d into a slotdisposed at an edge of third vertical panel 102 c.

In some aspects, at least two horizontal panels are configured to form alattice frame (e.g., first lattice frame 101) together with at least twovertical panels, where each of the at least two horizontal panels formsan edge of a set of internal rectangular spaces (including, for example,first internal rectangular space 111 a and second internal rectangularspace 111 b) defined by the at least two vertical panels. For example,as shown in FIG. 1 , first internal rectangular space 111 a is defined(e.g., at least partially surrounded) by a pair of opposing verticalinterior faces of first vertical panel 102 a and second vertical panel102 b, respectively, and a pair of opposing horizontal interior faces offirst horizontal panel 105 a and second horizontal panel 105 b,respectively. Likewise, as shown in FIG. 1 , second internal rectangularspace 111 b is defined (e.g., at least partially surrounded) by a pairof opposing vertical interior faces of first vertical panel 102 a andsecond vertical panel 102 b, respectively, and a pair of opposinghorizontal interior faces of second horizontal panel 105 b and fourthhorizontal panel 105 d, respectively.

According to some aspects, a vertical panel and a horizontal panel maybe retained, adhered, joined, and/or connected to each other by one ormore of a joint, a screw, a bolt, an adhesive, a magnet, a friction fitsystem, a bracket, etc. A friction fit system, or interference fit, is aform of fastening using at least two tightly mating parts or features toadhere the features by use of friction. In some cases, a friction fitsystem may include a crush system including a crusher feature orcrushing feature. The crusher feature may include a dimension that islarger than a crushing feature and may deform the crusher or crushingfeature, resulting in a lasting friction fit system.

In some cases, a lattice frame (e.g., first lattice frame 101) includesan outermost vertical panel (e.g., third vertical panel 102 c or fourthvertical panel 102 d) that might not be disposed between a pair ofvertical panels in the second direction. In some cases, an outermostvertical panel includes an outermost vertical face that faces away frommodular wall component 100 in the second direction. In some cases, anoutermost vertical panel forms an interior joint (such as a middlejoint, e.g., fifth interior joint 109 a) with a horizontal panel.

In some cases, a lattice frame (e.g., first lattice frame 101) includesan outermost horizontal panel (e.g., fourth horizontal panel 105 d) thatmight not be disposed between a pair of horizontal panels in the firstdirection. In some cases, the outermost horizontal panel includes anoutermost horizontal face that faces away from modular wall component100 in the first direction. In some cases, the outermost horizontalpanel forms an interior joint (such as a middle joint, e.g., sixthinterior joint 109 b) with a vertical panel.

In some cases, an outermost vertical panel (e.g., third vertical panel102 c) forms an interior joint (such as an end joint, e.g., ninthinterior joint 110) with an outermost horizontal panel (e.g., fourthhorizontal panel 105 d). In some cases, a pair of outermost verticalpanels and a pair of outermost horizontal panels partially surrounds aset of vertical panels and a set of horizontal panels to form a latticeframe (e.g., first lattice frame 101).

As shown in FIG. 1 , modular wall component 100 includes two latticeframes (e.g., first lattice frame 101 and second lattice frame 112).However, embodiments of the present disclosure are not limited thereto,and modular wall component 100 can include various numbers of latticeframes (such as one or more than two) oriented and/or split according tovarious installation specifications.

Second lattice frame 112 is an example of, or includes aspects of, thecorresponding element described with reference to FIG. 4 . A repeateddescription of one or more similar elements is omitted for the sake ofbrevity.

According to some aspects, a lattice frame (e.g., first lattice frame101 or second lattice frame 112) is arranged as a torsion box frame. Insome cases, the lattice frame provides strength and stiffness in thefirst (e.g., a vertical) direction, the second (e.g., a horizontal)direction, and the third (e.g., a shear) direction of modular wallcomponent 100. According to some aspects, a width in the third directionof a vertical panel is equal to a width in the third direction of ahorizontal panel and a depth of the lattice frame. According to someaspects, the depth of the lattice frame in the third direction is in therange of about three inches (e.g., three inches) to about five feet(e.g., five feet). According to some aspects, the depth of the latticeframe in the third direction is determined according to a mechanicalcomponent, an electrical component, or a plumbing component to bedisposed in modular wall component 100. According to some aspects, thedepth of the lattice frame in the third direction is determinedaccording to an external structure. According to some aspects, the depthof the lattice frame in the third direction is determined according to astandard lumber dimension.

In one aspect, second lattice frame 112 includes first additionalvertical panel 113 a, second additional vertical panel 113 b, thirdadditional vertical panel 113 c, fourth additional vertical panel 113 d,first additional horizontal panel 116 a, second additional horizontalpanel 116 b, first additional interior joint 119, second additionalinterior joint 120, third additional interior joint 121, and additionalinternal rectangular space 122.

First additional vertical panel 113 a and second additional verticalpanel 113 b are examples of, or include aspects of, the correspondingelements described with reference to FIG. 9 . Third additional verticalpanel 113 c is an example of, or includes aspects of, the correspondingelement described with reference to FIG. 4 . In one aspect, firstadditional vertical panel 113 a includes additional vertical interiorface 114 and additional vertical exterior face 115. First additionalhorizontal panel 116 a and second additional horizontal panel 116 b isan example of, or includes aspects of, the corresponding elementsdescribed with reference to FIG. 4 . In one aspect, first additionalhorizontal panel 116 a includes additional horizontal interior face 117and additional horizontal exterior face 118.

According to some aspects, second lattice frame 112 comprises at leasttwo additional vertical panels (e.g., first additional vertical panel113 a and second additional vertical panel 113 b) and at least twoadditional horizontal panels (e.g., first additional horizontal panel116 a and second additional horizontal panel 116 b), where each of theat least two additional horizontal panels is connected to each of the atleast two additional vertical panels by an interior joint (e.g., firstadditional interior joint 119, second additional interior joint 120, orthird additional interior joint 121), respectively.

As shown in FIG. 1 , first additional interior joint 119 (indicated bydashed lines) is a slot joint formed by first additional vertical panel113 a and first additional horizontal panel 116 a, second additionalinterior joint 120 (indicated by dashed lines) is a middle joint formedby first additional horizontal panel 116 a and fourth additionalvertical panel 113 d, and third additional interior joint 121 (indicatedby dashed lines) is an end joint formed by second additional horizontalpanel 116 b and fourth additional vertical panel 113 d.

According to some aspects, an additional vertical panel and anadditional horizontal panel may be retained, adhered, joined, and/orconnected to each other by one or more of a joint, a screw, a bolt, anadhesive, a magnet, a friction fit system, a bracket, etc.

As shown in FIG. 1 , second lattice frame 112 is joined to first latticeframe 101 to form modular wall component 100. In some cases, secondlattice frame 112 is joined to first lattice frame 101 via a joint (suchas a slot joint, a lap joint, a cross-lap joint, a 3D finger tenonjoint, etc.). In some cases, second lattice frame 112 is jointed tofirst lattice frame 101 via a screw, a bolt, an adhesives, a magnet,friction, or the like. In some cases, first lattice frame 101 and secondlattice frame 112 are joined via a friction-fit system, and may beinterlocked into one another via a joint system. According to someaspects, a depth of second lattice frame 112 in the third direction isequal to or different than the depth of first lattice frame 101 in thethird direction.

Split 123 is an example of, or includes aspects of, the correspondingelement described with reference to FIGS. 3-4 . In some cases, a splitbetween two or more lattice frames (such as split 123) may be aflat-planed interface (e.g., one or more points of contact) between thetwo or more lattice frames (e.g., first lattice frame 101 and secondlattice frame 112). In some examples, a split (e.g., an interface) is avertical split in which a vertical panel of a first lattice frame isjoined to an additional vertical panel of a second lattice frame. Insome examples, a split is a horizontal split in which a horizontal panelof a first lattice frame is joined to an additional horizontal panel ofa second lattice frame. In some cases, a split (e.g., an interface) maycomprise a curved or a three-dimensional interface. In some examples, asplit is a split in the depth direction in which one or more of avertical exterior face and a horizontal exterior face of a first latticeframe is joined to one or more of an additional vertical exterior faceand an additional horizontal exterior face of a second lattice frame. Asshown in FIG. 1 , split 123 is a horizontal split in which a horizontalpanel of first lattice frame 101 is joined to an additional horizontalpanel of second lattice frame 112.

Accordingly, in some aspects, a modular wall component such as modularwall component 100 may be provided as individual boxes/pieces/frames(e.g., a combination of components including one or more lattice framessuch as first lattice frame 101 and second lattice frame 112) that canbe separated from one another and joined to one another at one or moresplits (such as split 123). The modularity of the modular wall componentprovides the ability for one or more pieces of the modular wallcomponent to be carried or transferred through door openings, windowopenings, stairs, and the like. Therefore, the modular wall componentcan be designed and manufactured in ever-smaller modular components thatcan account for installation constraints and/or external factorsspecific to an installation setting.

In some cases, a split is oriented based on a geometry of an externalstructure, on a weight, size, and/or shape of one or more elements ofthe modular wall component, a geometry of an installation site of themodular wall component, or a combination thereof. For example, themodular wall component may be split based on installation factors suchas doorways used to access an installation site of the modular wallcomponent, or on external factors specific to the installation site suchas shapes, sizes, and/or locations of external components (e.g., sinks,toilets, washers, dryers, refrigerators, external water lines, externalelectrical lines, etc.), aspects of adjoining/adjacent walls installedor to be installed, aspects of adjoining/adjacent ceiling installed orto be installed, aspects of adjoining/adjacent floors installed or to beinstalled, additional componentry and devices installed or to beinstalled, finish componentry installed or to be installed (includingsinks, shower, cabinets), etc.

In an example, a split is oriented based on a horizontal vent line inwhich a washer and a dryer tie into a main stack (which may be, forexample, about eight inches above the counter height). As a result, insome cases, an electrical panel may be eight inches above the counterheight. In some cases, an electrical panel may be lower than a standardheight due to electronic componentry in the lower section.

According to some aspects, modular wall component 100 includes aplurality of features 124. However, embodiments of the presentdisclosure are not limited thereto, and a modular wall component mayinclude one feature. In some cases, a feature of the plurality offeatures 124 is a slot, a hole, a void, etc. of variable shape, size,orientation, and/or location that penetrates at least partially througha vertical panel, a horizontal panel, an additional vertical panel, oran additional horizontal panel. In some cases, a feature of theplurality of features 124 is shaped, sized, oriented, and/or located toaccommodate at least a portion of a mechanical component, an electricalcomponent, a plumbing component, or a combination thereof in thefeature. In some cases, the plurality of features 124 is configured toaccommodate an alignment of a mechanical component, an electricalcomponent, a plumbing component, an external component, or a combinationthereof. The plurality of features 124 is an example of, or includesaspects of, the corresponding element described with reference to FIGS.2, 4, and 7-9 .

First mounting panel 125 a is an example of, or includes aspects of, thecorresponding element described with reference to FIGS. 3-5 . Secondmounting panel 125 b is an example of, or includes aspects of, thecorresponding element described with reference to FIGS. 4 and 7 . Thirdmounting panel 125 c is an example of, or includes aspects of, thecorresponding element described with reference to FIG. 3 . Fourthmounting panel 125 d and fifth mounting panel 125 e are examples of, orinclude aspects of, the corresponding elements described with referenceto FIG. 10 .

According to some aspects, each of first mounting panel 125 a, secondmounting panel 125 b, third mounting panel 125 c, fourth mounting panel125 d, and fifth mounting panel 125 e is an example of a mounting panelof a set of mounting panels included in modular wall component 100.According to some aspects, a modular wall component may comprise one ormore mounting panels. According to some aspects, a mounting panel isomitted from a modular wall component. In some cases, a mounting panelextends in the second direction. In some cases, a face of the mountingpanel faces outwardly from modular wall component 100 in the thirddirection. According to some aspects, a mounting panel comprises a wood.According to some aspects, a mounting panel comprises at least one of awood, a wood composite, a plastic, a metal, or a masonry material(including, e.g., concrete or brick).

First mounting panel joint 126 a is an example of, or includes aspectsof, the corresponding element described with reference to FIG. 4 .Second mounting panel joint 126 b is an example of, or includes aspectsof, the corresponding element described with reference to FIG. 5 . Thirdmounting panel joint 126 c and fourth mounting panel joint 126 d areexamples of, or include aspects of, the corresponding elements describedwith reference to FIG. 7 . Fourth mounting panel joint 126 d is anexample of, or includes aspects of, the corresponding element describedwith reference to FIGS. 4 and 7 .

According to some aspects, a mounting panel is joined to an externalface of a vertical panel or an additional vertical panel by a mountingpanel joint (such as a slot joint, including a middle joint or an endjoint). For example, as shown in FIG. 1 , first mounting panel 125 a isjoined to first vertical panel 102 a by second mounting panel joint 126b, and first mounting panel 125 a is joined to third vertical panel 102c by first mounting panel joint 126 a.

According to some aspects, a mounting panel joint may be formed byinserting a tab extending from a vertical panel or an additionalvertical panel into a slot of a mounting panel. For example, as shown inFIG. 1 , first mounting panel joint 126 a is formed by inserting a tabextending from third vertical panel 102 c into a slot of first mountingpanel 125 a, second mounting panel joint 126 b is formed by inserting atab extending from first vertical panel 102 a into a slot of firstmounting panel 125 a, third mounting panel joint 126 c is formed byinserting a tab extending from second vertical panel 102 b into a slotof second mounting panel 125 b, and fourth mounting panel joint 126 d isformed by inserting a tab extending from third vertical panel 102 c intoa slot of second mounting panel 125 b. According to some aspects, amounting panel can be similarly joined to a horizontal panel or anadditional horizontal panel.

According to some aspects, a mounting panel may be retained, adhered,joined, and/or connected to one or more of a vertical panel, ahorizontal panel, an additional vertical panel, or an additionalhorizontal panel by one or more of a joint, a screw, a bolt, anadhesive, a magnet, a friction fit system, a bracket, or the like. Forexample, in some cases, a mounting panel and the one or more of avertical panel, a horizontal panel, an additional vertical panel, or anadditional horizontal panel are joined via a friction-fit system, andmay be interlocked into one another via a joint system.

According to some aspects, at least a portion of a vertical panel or anadditional vertical panel overlaps at least a portion of a mountingpanel in the third direction. For example, as shown in FIG. 1 , aportion of first vertical panel 102 a overlaps first mounting panel 125a in the third direction. According to some aspects, at least a portionof a horizontal panel or an additional horizontal panel overlaps atleast a portion of a mounting panel in the third direction. For example,as shown in FIG. 1 , a portion of first horizontal panel 105 a overlapssecond mounting panel 125 b in the third direction. For example,according to some aspects, an outwardly facing surface of a mountingpanel in the third direction is flush in the first direction with avertical panel and/or a horizontal panel.

In some cases, one or more features are disposed in a mounting panel andpenetrate at least partially through the mounting panel. In some cases,a mounting panel comprises a load attachment point. For example, in somecases, a mechanical component, an electrical component, a plumbingcomponent, or an external structure (such as a cabinet, an appliance,etc.) is attached to the mounting panel. According to some aspects, amounting panel is configured to be joined to a finish siding (such asplywood, drywall, etc.) to provide a finishing side for modular wallcomponent 100.

In some cases, a feature of the plurality of features 124 includes ashelf alignment hole used to locate a shelf without measuring. In anexample, a pair of features of the plurality of features 124 areimplemented as pilot holes that may be predrilled into a mounting panelto locate a shelf to be installed onto modular wall component 100. Inthe example, after one screw is installed into one of the features, theother feature is aligned, and the second screw is installed into theother feature, thereby avoiding use of a tape measure and a level by theinstaller of the shelf.

According to some aspects, a feature of the plurality of features 124 isembedded in one or more of a vertical panel, a horizontal panel, anadditional vertical panel, an additional horizontal panel, or a mountingpanel. For example, in some cases, a numerical control (NC) program isused to calculate and determine locations of one or more features of theplurality of features 124. In some cases, a computer numerical control(CNC) machine uses the NC program to locate and subtract the one or morefeatures from one or more of a vertical panel, a horizontal panel, anadditional vertical panel, an additional horizontal panel, or a mountingpanel. In some cases, a feature of the plurality of features 124 isformed using an additive manufacturing process, a subtractivemanufacturing process, or a combination thereof.

According to some aspects, one or more of a vertical panel, a horizontalpanel, an additional vertical panel, an additional horizontal panel, ora mounting panel are formed via a subtractive process, injectionmolding, 3D printing, or any other suitable manufacturing method.

According to some aspects, a vertical panel can be interconnected with ahorizontal panel via a screw, a bolt, adhesive, a magnet, friction, orthe like. According to some aspects, an additional vertical panel can beinterconnected with an additional horizontal panel via a screw, a bolt,adhesive, a magnet, friction, or the like. According to some aspects, amounting panel can be interconnected with a vertical panel, a horizontalpanel, an additional vertical panel, an additional horizontal panel, ora combination thereof via a screw, a bolt, adhesive, a magnet, friction,or the like.

According to some aspects, one or more of an interior joint, anadditional interior joint, or a mounting panel joint is implemented as aslot joint, a lap joint, a cross-lap joint, a 3D finger tenon joint, orany other suitable joint.

First buttress 127 and buttress joint 128 are examples of, or includeaspects of, the corresponding elements described with reference to FIG.4 . According to some aspects, a buttress (such as first buttress 127)contacts at least two of a group including a vertical panel, ahorizontal panel, an additional vertical panel, and an additionalhorizontal panel. According to some aspects, a buttress is joined to oneor more of a vertical panel, a horizontal panel, an additional verticalpanel, and an additional horizontal panel 116 via a buttress joint (suchas buttress joint 128). In some cases, a buttress joint is a slot joint(for example, a slot joint, a middle joint, or an end joint). In somecases, a buttress (e.g., first buttress 127) provides additionalstructural rigidity for modular wall component 100. In some cases, abuttress comprises a wood, a wood composite, a plastic, a metal, amasonry material (including, e.g., concrete or brick), or a combinationthereof. In some cases, a buttress (e.g., first buttress 127) and/or abuttress joint (e.g., buttress joint 128) are included in one or morelattice frames (e.g., first lattice frame 101 and/or second latticeframe 112). First buttress 127 and buttress joint 128 are examples of,or include aspects of, the corresponding elements described withreference to FIG. 4 .

According to some aspects, modular wall component 100 can be at leastpartially enclosed on one or more exterior sides that face away frommodular wall component 100 in the third direction (for example, byattaching a facade panel, such as plywood, to a vertical exterior face104, a horizontal exterior face 107, an additional vertical exteriorface 115, an additional horizontal exterior face 118, a mounting panel125, or a combination thereof).

According to some aspects, modular wall component 100 includes anintegrated pickup for a crane attachment. As a result, a crane orsecondary equipment can pick up and place modular wall component 100(e.g., for installation). According to some aspects, modular wallcomponent 100 includes backing for American Disabilities Act (ADA)components and bracketry. According to some aspects, modular wallcomponent 100 includes integrated attachment points for attachingmodular wall component 100 to a ceiling, a wall, and/or a floor.

FIG. 2 shows an example of a modular wall component 200 includingplumbing components according to aspects of the present disclosure.Modular wall component 200 is an example of, or includes aspects of, thecorresponding element described with reference to FIGS. 1, and 3-15 . Arepeated description of one or more similar elements is omitted for thesake of brevity.

According to some aspects, modular wall component 200 is an integratedassembly that can function as both a wall and as an MEP containmentstructure. In some cases, items such as water lines, outlets, a waterheater, and the like can be preinstalled in modular wall component 200,and modular wall component 200 can be shipped and installed as a singleunit. In some examples, modular wall component 200 can be installed orlocated behind a kitchen, a bathroom, a laundry room, or the like. Forexample, in some cases, modular wall component 200 can function as asingle wall structure disposed between a bathroom and a kitchen, andmodular wall component 200 can include MEP componentry to support thebathroom and the kitchen (e.g., to support external bathroom and kitchencomponents such as sinks, toilets, stove tops, refrigerators, etc.).

According to some aspects, one or more of a mechanical component, anelectrical component, or a plumbing component is attached to an elementof modular wall component 200 via an attachment mechanism such as abracket, a bolt, a screw, an adhesive, a magnet, or any other suitableattachment mechanism. According to some aspects, the attachmentmechanism is placed in or on modular wall component 200 at apredetermined location.

In one aspect, modular wall component 200 includes first plumbingcomponent 205, second plumbing component 210, third plumbing component215, fourth plumbing component 220, fifth plumbing component 225, sixthplumbing component 230, seventh plumbing component 235, and a pluralityof features 240.

First plumbing component 205 is an example of, or includes aspects of,the corresponding element described with reference to FIGS. 3, 4, 6, and8-10 . Second plumbing component 210 is an example of, or includesaspects of, the corresponding element described with reference to FIGS.4 and 8 . Third plumbing component 215 is an example of, or includesaspects of, the corresponding element described with reference to FIG. 8. Fifth plumbing component 225 is an example of, or includes aspects of,the corresponding element described with reference to FIGS. 4 and 6 .Sixth plumbing component 230 is an example of, or includes aspects of,the corresponding element described with reference to FIG. 6 . Seventhplumbing component 235 is an example of, or includes aspects of, thecorresponding element described with reference to FIG. 7 . The pluralityof features 240 is an example of, or includes aspects of, thecorresponding element described with reference to FIGS. 1, 4, 7, and 8 .

Referring to FIG. 2 , first plumbing component 205, second plumbingcomponent 210, third plumbing component 215, fourth plumbing component220, fifth plumbing component 225, sixth plumbing component 230, andseventh plumbing component 235 are respectively partially disposed inthe plurality of features 240. However, embodiments of the presentdisclosure are not limited thereto, and according to some aspects, oneor more of a mechanical component, an electrical component, a plumbingcomponent, or a combination thereof are disposed in modular wallcomponent 200 and/or the plurality of features 240.

As shown in FIG. 2 , each of first plumbing component 205, secondplumbing component 210, and third plumbing component 215 are a waterline or a pipe, each of fourth plumbing component 220, fifth plumbingcomponent 225, and sixth plumbing component 230 is a connectingcomponent for respectively connecting an external component to firstplumbing component 205, second plumbing component 210, and thirdplumbing component 215, and seventh plumbing component 235 is a waterbox for a refrigerator.

According to some aspects, the plurality of features 240 are located inmodular wall component 200 to provide readily identifiable for positionsof a mechanical component, an electrical component, a plumbingcomponent, or a combination thereof in modular wall component 200. Insome cases, a layout of the plurality of features 240 is determinedaccording to a planned layout for the mechanical component, theelectrical component, the plumbing component, or the combination thereofwithing modular wall component 200. In some cases, one or more featuresof the plurality of features 240 provides an ability for modular wallcomponent 200 to restrain movement of the mechanical component, theelectrical component, the plumbing component to a predetermined rangeand location.

According to some aspects, modular wall component 200 provides for aplumbing component (such as a water line) to be set back from anexterior wall of a building to avoid possible damage that may be causedby the use of long screws. In some cases, modular wall component 200includes an embedded or integrated water shut-off valve with accessthrough an access hole/panel. In some cases, the access may be through akitchen cabinet sink. In some cases, modular wall component 200 includeswasher and dryer connections.

According to some aspects, a plumbing component including cross-linkedpolyethylene (PEX) is included in modular wall component 200, but thepresent disclosure is not limited thereto. For example, copper or anyother suitable material for a plumbing component may be used in aplumbing component. In some cases, modular wall component 200 includesone or more standard manifolds for the PEX plumbing to minimizeconnection points where failures are more likely to occur.

In some cases, modular wall component 200 includes a stub-out. In somecases, the stub-out is standard or is pre-manufactured. In some cases, astandard brass stub-out is assembled and coiled/placed inside modularwall component 200 prior to final assembly of modular wall component200. In some cases, the stub-out is mounted with one or more screws inpre-drilled locations of modular wall component 200 during finalassembly of modular wall component 200. In some cases, modular wallcomponent 200 includes PEX plumbing, and the stub-out is at leastpartially retracted into modular wall component 200 for shipping.

According to some aspects, the plumbing component is manufacturedseparately from modular wall component 200 and installed aftermanufacturing. In some cases, the plumbing component is installed in oneor more features of the plurality of features 240 of modular wallcomponent 200. According to some aspects, a backing piece is attached tomodular wall component 200 and constrains a movement of the plumbingcomponent in the third direction.

According to some aspects, modular wall component 200 includes one ormore electrical components, such as a wire, an electrical connection, apanel, an outlet, a switch, etc. In some cases, a load center may belocated in modular wall component 200 to provide a convenient locationfor an electrical panel so electrical wiring may route into modular wallcomponent 200. In some cases, one or more features of the plurality offeatures 240 are implemented as a pilot hole for an electrical componentso a worker may avoid performing secondary alignment at an installationsite of modular wall component 200.

According to some aspects, one or more features of the plurality offeatures 240 are located a sufficient distance in the third directionfrom a piece of drywall adjacent to or joined to modular wall component200 so the wiring may be placed in modular wall component 200 withoutadditional hardware.

According to some aspects, the electrical component is a cabinet box(for example, for one or more LED lights). In some cases, the cabinetbox includes electrical routing. In some cases, a power supply (e.g., aDC or an AC power supply) and a junction box are embedded in modularwall component 200 via one or more features of the plurality of features240, and a cover of the junction box is used for access to the powersupply.

According to some aspects, the electrical component is a light. In somecases, the light is controlled via a wired or a wireless connection. Insome cases, one or more switches may be used with a magnetic back suchthat a switch may be placed in a surface-mounted junction box cover. Insome cases, a light junction box includes a plate at a predetermineddepth such that a mud ring is omitted.

FIG. 3 shows an example of a back view of the modular wall component ofFIG. 2 according to aspects of the present disclosure. Modular wallcomponent 300 is an example of, or includes aspects of, thecorresponding element described with reference to FIGS. 1, 2, and 4-15 .A repeated description of one or more similar elements is omitted forthe sake of brevity.

In one aspect, modular wall component 300 includes first vertical panel305, first horizontal panel 310, first interior joint 315, firstmounting panel 320, third mounting panel 325, fourth mounting paneljoint 330, second buttress 335, third buttress 340, split 345, and firstplumbing component 350.

First vertical panel 305 is an example of, or includes aspects of, thecorresponding element described with reference to FIGS. 1 and 5 . Firsthorizontal panel 310 is an example of, or includes aspects of, thecorresponding element described with reference to FIGS. 1, 4, and 6-7 .First interior joint 315 is an example of, or includes aspects of, thecorresponding element described with reference to FIG. 1 . Firstmounting panel 320 is an example of, or includes aspects of, thecorresponding element described with reference to FIGS. 1 and 4-5 .Third mounting panel 325 is an example of, or includes aspects of, thecorresponding element described with reference to FIG. 1 . Secondbuttress 335 and third buttress 340 are examples of, or include aspectsof, a buttress as described with reference to FIG. 1 and thecorresponding elements described with reference to FIG. 4 . Split 345 isan example of, or includes aspects of, the corresponding elementdescribed with reference to FIGS. 1 and 4 . First plumbing component 350is an example of, or includes aspects of, the corresponding elementdescribed with reference to FIGS. 2, 4, 6, and 8-10 .

FIG. 3 shows a side of the modular wall component of FIG. 2 that facesoutwardly in an opposite third direction from the side of the outwardlyfacing side of the modular wall component shown in FIG. 2 . As shown inFIG. 3 , first vertical panel 305 and first horizontal panel 310 formfirst interior joint 315 as a slot joint (indicated within dottedlines). As shown by FIG. 1 and FIG. 3 , one or more slot joints(including, e.g., first interior joint 315) provides for a verticalpanel (e.g., first vertical panel 305) to contact one or more horizontalpanels by slotting into the one or more horizontal panels, and for ahorizontal panel (e.g., first horizontal panel 310) to contact one ormore vertical panels by slotting into the one or more vertical panels.

As shown in FIG. 3 , in some cases, a mounting panel joint (e.g., fourthmounting panel joint 330, indicated within dashed lines) may be formedas a slot joint between a mounting panel (e.g., third mounting panel325) and a vertical panel (e.g., first vertical panel 305).

As shown in FIG. 3 , second buttress 335 and third buttress 340 aredisposed adjacent to each other on opposing sides of split 345 inmodular wall component 300. In some cases, a buttress (including, e.g.,each of second buttress 335 and third buttress 340) may be an integrallypositioned component that may provide additional structural support forthe modular wall component 300. As shown in FIG. 3 , second buttress 335and third buttress 340 are a mirrored shape of one another, but thepresent disclosure is not limited thereto, and one or more buttressesmay be of different shapes from each other.

As shown in FIG. 3 , at least some of first plumbing component 350 isdisposed in a space between first mounting panel 320 and third mountingpanel 325. As shown in FIG. 3 , first mounting panel 320 and thirdmounting panel 325 are disposed on opposite sides of modular wallcomponent 300 in the third direction.

FIG. 4 shows an example of a side view of the modular wall component ofFIG. 2 according to aspects of the present disclosure. Modular wallcomponent 400 is an example of, or includes aspects of, thecorresponding element described with reference to FIGS. 1-3 and 5-15 . Arepeated description of one or more similar elements is omitted for thesake of brevity.

FIG. 4 shows a view facing third vertical panel 402 of modular wallcomponent 400 in the second direction. Third vertical panel 402 is anexample of, or includes aspects of, the corresponding element describedwith reference to FIGS. 1 and 6-7 .

In one aspect, modular wall component 400 includes first lattice frame401, second lattice frame 410, split 414, a plurality of features 415,first mounting panel 416, second mounting panel 417, first mountingpanel joint 418, fourth mounting panel joint 419, first buttress 420,buttress joint 421, first plumbing component 422, second plumbingcomponent 423, sixth plumbing component 424, and seventh plumbingcomponent 425.

First lattice frame 401 and second lattice frame 410 are examples of, orinclude aspects of, the corresponding elements described with referenceto FIG. 1 . Split 414 is an example of, or includes aspects of, thecorresponding element described with reference to FIGS. 1 and 3 . Theplurality of features 415 is an example of, or includes aspects of, thecorresponding element described with reference to FIGS. 1, 2, 7, and 8 .First mounting panel 416 is an example of, or includes aspects of, thecorresponding element described with reference to FIGS. 1, 3 , and 5.Second mounting panel 417 is an example of, or includes aspects of, thecorresponding elements described with reference to FIGS. 1 and 7 . Firstmounting panel joint 418 (indicated within dashed lines) is an exampleof, or includes aspects of, the corresponding element described withreference to FIG. 1 . Fourth mounting panel joint 419 (indicated withindashed lines) is an example of, or includes aspects of, thecorresponding element described with reference to FIGS. 1 and 7 .

First buttress 420 and buttress joint 421 (indicated within dashedlines) are examples of, or include aspects of, the correspondingelements described with reference to FIG. 1. First plumbing component422 is an example of, or includes aspects of, the corresponding elementdescribed with reference to FIGS. 2, 3, 6, and 8-10 . Second plumbingcomponent 423 is an example of, or includes aspects of, thecorresponding element described with reference to FIGS. 2 and 8 . Sixthplumbing component 424 is an example of, or includes aspects of, thecorresponding element described with reference to FIGS. 2 and 6 .Seventh plumbing component 425 is an example of, or includes aspects of,the corresponding element described with reference to FIG. 2 .

In one aspect, first lattice frame 401 includes third vertical panel402, first horizontal panel 403, second horizontal panel 404, thirdhorizontal panel 405, fourth horizontal panel 406, seventh interiorjoint 407, eighth interior joint 408, and ninth interior joint 409.First horizontal panel 403 is an example of, or includes aspects of, thecorresponding element described with reference to FIGS. 1, 3, and 6-7 .Second horizontal panel 404 is an example of, or includes aspects of,the corresponding element described with reference to FIGS. 1 and 5 .Third horizontal panel 405 is an example of, or includes aspects of, thecorresponding element described with reference to FIGS. 1 and 7 . Fourthhorizontal panel 406 is an example of, or includes aspects of, thecorresponding element described with reference to FIGS. 1 and 5 .Seventh interior joint 407 (indicated within dashed lines) is an exampleof, or includes aspects of, the corresponding element described withreference to FIGS. 1 and 6-7 . Eighth interior joint 408 (indicatedwithin dashed lines) is an example of, or includes aspects of, thecorresponding element described with reference to FIGS. 1 and 7 . Ninthinterior joint 409 (indicated within dashed lines) is an example of, orincludes aspects of, the corresponding element described with referenceto FIG. 1 .

In one aspect, second lattice frame 410 includes third additionalvertical panel 411, first additional horizontal panel 412, and secondadditional horizontal panel 413. Third additional vertical panel 411,first additional horizontal panel 412, and second additional horizontalpanel 413 are examples of, or include aspects of, the correspondingelements described with reference to FIG. 1 .

FIG. 5 shows an example of a horizontal perspective cross-sectional viewof the modular wall component of FIG. 2 according to aspects of thepresent disclosure. Modular wall component 500 is an example of, orincludes aspects of, the corresponding element described with referenceto FIGS. 1-4 and 6-15 . A repeated description of one or more similarelements is omitted for the sake of brevity.

In one aspect, modular wall component 500 includes first vertical panel505, second horizontal panel 510, third interior joint 515, fourthhorizontal panel 520, sixth interior joint 525, first mounting panel530, and second mounting panel joint 535.

First vertical panel 505 is an example of, or includes aspects of, thecorresponding element described with reference to FIGS. 1 and 3 . Secondhorizontal panel 510 is an example of, or includes aspects of, thecorresponding element described with reference to FIGS. 1 and 4 . Thirdinterior joint 515 (indicated within dashed lines) is an example of, orincludes aspects of, the corresponding element described with referenceto FIG. 1 . Fourth horizontal panel 520 is an example of an outermosthorizontal panel described with reference to FIGS. 1 and 4 . Sixthinterior joint 525 (indicated within dashed lines) is an example of, orincludes aspects of, the corresponding element described with referenceto FIG. 1 . First mounting panel 530 is an example of, or includesaspects of, the corresponding element described with reference to FIGS.1 and 3 . Second mounting panel joint 535 (indicated within dashedlines) is an example of, or includes aspects of, the correspondingelement described with reference to FIG. 1 .

Referring to FIG. 5 , a cross-section of first vertical panel 505 showsthe arrangement of respective portions of first vertical panel 505 andsecond horizontal panel 510 to form third interior joint 515. Forexample, FIG. 5 shows a cross-section of third interior joint 515, andthat third interior joint 515 is a slot joint. Likewise, FIG. 5 showsthe arrangement of respective portions of first vertical panel 505 andfourth horizontal panel 520 to form sixth interior joint 525. Forexample, FIG. 5 shows a cross-section of sixth interior joint 525.Furthermore, FIG. 5 shoes the arrangement of first vertical panel 505and first mounting panel 530 to form second mounting panel joint 535.For example, FIG. 5 shows a cross-section of second mounting panel joint535.

FIG. 6 shows an example of a vertical cross-sectional view of themodular wall component of FIG. 2 according to aspects of the presentdisclosure. Modular wall component 600 is an example of, or includesaspects of, the corresponding element described with reference to FIGS.1-5 and 7-15 . A repeated description of one or more similar elements isomitted for the sake of brevity.

In one aspect, modular wall component 600 includes first horizontalpanel 605, second vertical panel 610, second interior joint 615, thirdvertical panel 620, seventh interior joint 625, first plumbing component630, fifth plumbing component 635, and sixth plumbing component 640.

First horizontal panel 605 is an example of, or includes aspects of, thecorresponding element described with reference to FIGS. 1, 3-4, and 7 .Second vertical panel 610 is an example of, or includes aspects of, thecorresponding element described with reference to FIGS. 1 and 7 . Secondinterior joint 615 (indicated within dashed lines) is an example of, orincludes aspects of, the corresponding element described with referenceto FIGS. 1 and 7 . Third vertical panel 620 is an example of, orincludes aspects of, the corresponding element described with referenceto FIGS. 1, 4, and 7 . Seventh interior joint 625 (indicated withindashed lines) is an example of, or includes aspects of, thecorresponding element described with reference to FIGS. 1, 4, and 7 .

First plumbing component 630 is an example of, or includes aspects of,the corresponding element described with reference to FIGS. 2-4 and 8-10. Fifth plumbing component 635 is an example of, or includes aspects of,the corresponding element described with reference to FIGS. 2 and 4 .Sixth plumbing component 640 is an example of, or includes aspects of,the corresponding element described with reference to FIG. 2 .

Referring to FIG. 6 , a cross-section of first horizontal panel 605shows a top-down view in the first direction of a cross-section ofsecond interior joint 615 formed by first horizontal panel 605 andsecond vertical panel 610, a cross-section of seventh interior joint 625formed by first horizontal panel 605 and third vertical panel 620, and across-section of first plumbing component 630.

FIG. 7 shows an example of a vertical perspective cross-sectional viewof the modular wall component of FIG. 2 according to aspects of thepresent disclosure. Modular wall component 700 is an example of, orincludes aspects of, the corresponding element described with referenceto FIGS. 1-6 and 8-15 . A repeated description of one or more similarelements is omitted for the sake of brevity.

In one aspect, modular wall component 700 includes first horizontalpanel 705, second vertical panel 710, second interior joint 715, thirdvertical panel 720, seventh interior joint 725, third horizontal panel730, eighth interior joint 735, second mounting panel 740, thirdmounting panel joint 745, fourth mounting panel joint 750, and aplurality of features 755.

First horizontal panel 705 is an example of, or includes aspects of, thecorresponding element described with reference to FIGS. 1, 3-4, and 6 .Third horizontal panel 730 is an example of, or includes aspects of, thecorresponding element described with reference to FIGS. 1 and 4 . Secondvertical panel 710 is an example of, or includes aspects of, thecorresponding element described with reference to FIG. 1 . Secondinterior joint 715 (indicated within dashed lines) is an example of, orincludes aspects of, the corresponding element described with referenceto FIGS. 1 and 6 . Third vertical panel 720 is an example of, orincludes aspects of, the corresponding element described with referenceto FIGS. 1, 4, and 6 . Seventh interior joint 725 (indicated withindashed lines) is an example of, or includes aspects of, thecorresponding element described with reference to FIGS. 1, 4, and 6 .Eighth interior joint 735 (indicated within dashed lines) is an exampleof, or includes aspects of, the corresponding element described withreference to FIGS. 1 and 4 .

Second mounting panel 740 is an example of, or includes aspects of, thecorresponding element described with reference to FIGS. 1 and 4 . Thirdmounting panel joint 745 (indicated within dashed lines) and fourthmounting panel joint 750 (indicated within dashed lines) are examplesof, or include aspects of, the corresponding elements described withreference to FIGS. 1 and 4 . The plurality of features 755 are examplesof, or include aspects of, the corresponding element described withreference to FIGS. 1-2 and 8-9 .

Referring to FIG. 7 , a cross-section of first horizontal panel 705shows a cross-section of second interior joint 715 formed by firsthorizontal panel 705 and second vertical panel 710 and a cross-sectionof seventh interior joint 725 formed by first horizontal panel 705 andthird vertical panel 720.

FIG. 7 also shows that eighth interior joint 735 is formed by thirdvertical panel 720 and third horizontal panel 730, third mounting paneljoint 745 is formed by second vertical panel 710 and second mountingpanel 740, and fourth mounting panel joint 750 is formed by thirdvertical panel 720 and second mounting panel 740.

FIG. 7 also shows that a mounting panel (such as second mounting panel740) may include a plurality of features (such as plurality of features755). As shown in FIG. 7 , the plurality of features may include aseries of guide holes for mounting one or more external components to amounting panel.

FIG. 8 shows an example of a perspective detail view of the modular wallcomponent of FIG. 2 according to aspects of the present disclosure.Modular wall component 800 is an example of, or includes aspects of, thecorresponding element described with reference to FIGS. 1-7 and 9-15 . Arepeated description of one or more similar elements is omitted for thesake of brevity.

In one aspect, modular wall component 800 includes first plumbingcomponent 805, second plumbing component 810, third plumbing component815, first feature 820, second feature 825, third feature 830, andfourth feature 835. First plumbing component 805 is an example of, orincludes aspects of, the corresponding element described with referenceto FIGS. 2-4, 7, 9, and 10 . Second plumbing component 810 is an exampleof, or includes aspects of, the corresponding element described withreference to FIGS. 2 and 4 . Third plumbing component 815 is an exampleof, or includes aspects of, the corresponding element described withreference to FIG. 2 . Each of first feature 820, second feature 825,third feature 830, and fourth feature 835 is a feature of the pluralityof features described with reference to FIGS. 1, 2, 4, 7, and 9 .

Referring to FIG. 8 , one or more MEP components and/or datainfrastructure components may be routed through one or more features.For example, as shown in FIG. 8 , first plumbing component 805 is routedthrough first feature 820, each of second plumbing component 810 andthird plumbing component 815 is routed through second feature 825,second plumbing component 810 is routed through third feature 830, andthird plumbing component 815 is routed through fourth feature 835.

FIG. 9 shows an example of a perspective detail view of the modular wallcomponent of FIG. 2 according to aspects of the present disclosure.Modular wall component 900 is an example of, or includes aspects of, thecorresponding element described with reference to FIGS. 1-8, and 10-15 .A repeated description of one or more similar elements is omitted forthe sake of brevity.

In one aspect, modular wall component 900 includes first additionalvertical panel 905, second additional vertical panel 910, fifth feature915, sixth feature 920, and first plumbing component 925. Firstadditional vertical panel 905 and second additional vertical panel 910are examples of, or include aspects of, the corresponding elementsdescribed with reference to FIG. 1 . In one aspect, each of fifthfeature 915 and sixth feature 920 are features of the plurality offeatures described with reference to FIGS. 1, 2, 4, 7, and 8 . Firstplumbing component 925 is an example of, or includes aspects of, thecorresponding element described with reference to FIGS. 2-4, 7, 8, and10 .

Referring to FIG. 9 , in some cases, one or more features are orientedto provide a natural slope to a component at least partially disposedwithin the one or more features. For example, in some cases, anon-pressurized plumbing component may operate using gravity, and so maybe pitched at a downwardly sloping angle. As shown in FIG. 9 , a bottomof fifth feature 915 is disposed at a higher height in the firstdirection than a bottom of sixth feature 920, providing an ability forfirst plumbing component 925 to respectively pass through the firstadditional vertical panel 905 and second additional vertical panel 910at a downwardly sloping angle so that a fluid may pass through firstplumbing component 925 via gravity.

In some cases, one or more features of a modular wall component (such asmodular wall component 900) are oversized for simple installation andadjustment of a component during or after installation of the modularwall component. For example, in some cases, prior to shipment of themodular wall component to an installation site, a plumbing component, amechanical component, an electric component, or a combination thereofmay be temporarily set within the modular wall component. In some cases,when the modular wall component is ready to be installed, a user canunset the temporary sets and permanently or semi-permanently set theplumbing component, the mechanical component, the electric component, orthe combination thereof in place.

FIG. 10 shows an example of a front detail view of the modular wallcomponent of FIG. 2 according to aspects of the present disclosure.Modular wall component 1000 is an example of, or includes aspects of,the corresponding element described with reference to FIGS. 1-9 and11-15 . A repeated description of one or more similar elements isomitted for the sake of brevity.

In one aspect, modular wall component 1000 includes first plumbingcomponent 1005, fourth mounting panel 1010, and fifth mounting panel1015.

First plumbing component 1005 is an example of, or includes aspects of,the corresponding element described with reference to FIGS. 2-4 and 7-9. Fourth mounting panel 1010 and fifth mounting panel 1015 are examplesof, or include aspects of, the corresponding elements described withreference to FIG. 1 .

Referring to FIG. 10 , fourth mounting panel 1010 and fifth mountingpanel 1015 are disposed on opposing sides of modular wall component 1000in the third direction, and first plumbing component 1005 is disposed ina space between fourth mounting panel 1010 and fifth mounting panel1015.

FIG. 11 shows an example of a modular wall component 1100 installationaccording to aspects of the present disclosure. The example shownincludes modular wall component 1100, first external structure 1105,second external structure 1110, and third external structure 1115.Modular wall component 1100 is an example of, or includes aspects of,the corresponding element described with reference to FIGS. 1-10, and12-15 . A repeated description of one or more similar elements isomitted for the sake of brevity.

Referring to FIG. 11 , in some cases, a modular wall component such asmodular wall component 1100 is installed alongside one or more externalstructures. As shown, modular wall component 1100 is installed alongsidefirst external structure 1105 (e.g., a set of cabinets), second externalstructure 1110 (e.g., a ceiling structure), and third external structure1115 (e.g., a wall structure). For example, in some cases, FIG. 11 showsa kitchen. In some cases, each of first external structure 1105, secondexternal structure 1110, and third external structure 1115 are joinedwith modular wall component 1100 at various points of modular wallcomponent 1100 (including, for example, a mounting panel, a verticalpanel, a horizontal panel, or a combination thereof as described withreference to FIG. 1 ). In some cases, a reinforcement component (such asa brace, a panel, a bar, etc.) is included in modular wall component1100 to help modular wall component 1100 to support at least one offirst external structure 1105, second external structure 1110, or thirdexternal structure 1115.

In some cases, one or more cabinets of first external structure 1105 maybe expanded or retracted to be set to different depths away from modularwall component 1100. For example, if a customer desires a thickerbacksplash in the kitchen, a user may move a cabinet box in relation tomodular wall component 1100 without using a secondary extension piece.In some cases, a degree of recession of one or more outlets (or othercomponents) into modular wall component 1100 can be likewise adjusted.

As shown, modular wall component 1100 can include a plurality of latticeframes as described with reference to FIG. 1 . In some cases, a finishpanel (such as a drywall panel) is disposed between modular wallcomponent 1100 and first external structure 1105. A finish panel isomitted from FIG. 11 between modular wall component 1100 and firstexternal structure 1105 for an ease of illustrating modular wallcomponent 1100.

According to some aspects, a modular wall component such as modular wallcomponent 1100 may act as a structural substrate, replacing atraditionally framed wall. For example, the traditionally framed wallmay be an array of vertical or horizontal sections of lumber, extendingfrom a floor to a ceiling structure. The traditionally framed wall mayinclude lumber that is adjacent to MEP componentry, as well asinsulation. For example, in some cases, modular wall component 1100 isdisposed between a first and second layer of drywall, between tongue andgroove paneling, or between any other suitable external finish material.Accordingly, in some cases, modular wall component 1100 can function aseither a structural wall or as a non-structural wall.

In some cases, a modular wall component such as modular wall component1100 may abut against a traditionally framed wall component (such asthird external structure 1115), but embodiments of the presentdisclosure are not limited thereto. For example, in some cases, modularwall component 1100 may abut against a wall including cross-laminatedtimber (CLT), mass timber, glue-laminated timber (GLT), a mass plywoodpanel, or other engineered timber product. In some cases, modular wallcomponent 1100 abuts against drywall, tongue and groove paneling, or anyother suitable external finish material. According to some aspects,shelving and finish materials can be installed in or on predeterminedlocations of modular wall component 1100 for a seamless appearance.

According to some aspects, one or more modular wall components 1100 maybe used in any orientation or configuration to provide a buildinginterior configuration. For example, in some cases, a kitchen may beadjacent to a laundry room. As a result, one or more modular wallcomponents 1100 may be disposed within and/or between the kitchen andthe laundry room to provide MEP componentry for the kitchen and thelaundry room.

Installing a Modular Wall Component

FIGS. 12-15 show an example of installing a modular wall componentaccording to aspects of the present disclosure. The example shown inFIG. 12 includes modular wall component 1200 and adjacent wall 1205.Modular wall component 1200 is an example of, or includes aspects of,the corresponding element described with reference to FIGS. 1-11, and13-15 . Adjacent wall 1205 is an example of, or includes aspects of, thecorresponding element described with reference to FIGS. 13-15 .

Referring to FIG. 12 , in an example, modular wall component 1200 isinstalled at an installation site (for example, on a floor). In somecases, modular wall component 1200 is adjusted prior to or duringinstallation (for example, by adjusting a position, size, or orientationof one or more elements of modular wall component 1200) to accommodate atolerance of the floor. Adjacent wall 1205 is joined to modular wallcomponent 1200 (for example, by a joint, a screw, a bolt, a bracket,etc.).

In some cases, a lower piece of modular wall component 1200 (such as alower lattice frame) includes a cutout so modular wall component 1200can be placed where, for example, a cabinet would be placed. Then,modular wall component 1200 can be slid into place without touching oraffecting, for example, a plumbing component or an electrical componentthat may be disposed outside of surrounding material (such as concrete).Then, the upper piece of the two pieces (e.g., an upper lattice frame)can be set on the lower piece, separated from an exterior or rearwardwall, and slid into place. As a result, connections for an externalappliance, such as a microwave, a solar conduit, etc., can be made priorto full installation of modular wall component 1200. Therefore, a simpleand easy process for installation of modular wall component 1200 may beachieved.

In some cases, a split in modular wall component 1200 (such as the splitdescribed with reference to FIG. 1 ) may be oriented based on one ormore sink stub outs. For instance, in some cases, an area around one ormore sink stub outs may be empty and may include a connection to afoundation of the installation site. In some cases, by moving the splitto the one or more sink stub outs, more electrical componentry may beincluded in the load center, such as the microwave or water heater.Additionally or alternatively, in some cases, water lines are runfurther up in modular wall component 1200 towards the water heater.

The example shown in FIG. 13 includes modular wall component 1300,adjacent wall 1305, and adjacent ceiling 1310. Modular wall component1300 is an example of, or includes aspects of, the corresponding elementdescribed with reference to FIGS. 1-12, 14, and 15 . Adjacent wall 1305is an example of, or includes aspects of, the corresponding elementdescribed with reference to FIGS. 12 and 14-15 . Adjacent ceiling 1310is an example of, or includes aspects of, the corresponding elementdescribed with reference to FIGS. 14-15 .

Referring to FIG. 13 , adjacent ceiling 1310 is attached to modular wallcomponent 1300 and adjacent wall 1305 (for example, by a joint, a screw,a bolt, a bracket, etc.). In some cases, modular wall component 1300 isadjusted prior to or during installation (for example, by adjusting aposition, size, or orientation of one or more elements of modular wallcomponent 1200) to accommodate a tolerance of adjacent ceiling 1310.

The example shown in FIG. 14 includes modular wall component 1400,adjacent wall 1405, adjacent ceiling 1410, and additional componentry1415. Modular wall component 1400 is an example of, or includes aspectsof, the corresponding element described with reference to FIGS. 1-13,and 15 . Adjacent wall 1405 is an example of, or includes aspects of,the corresponding element described with reference to FIGS. 12-13 and 15. Adjacent ceiling 1410 is an example of, or includes aspects of, thecorresponding element described with reference to FIGS. 13 and 15 .Additional componentry 1415 is an example of, or includes aspects of,the corresponding element described with reference to FIG. 15 .

Referring to FIG. 14 , additional componentry 1415 (such as a waterheater) is installed on adjacent ceiling 1410. In some cases, additionalcomponentry 1415 is connected to at least one of a mechanical component,an electrical component, or a plumbing component disposed in modularwall component 1400.

In an example, armored cables may be used for the water heater. In somecases, the armored cable is coiled up at the top of modular wallcomponent 1400 such that the armored cable runs straight to the waterheater without additional paneling added to modular wall component 1400.In another example, a conduit line disposed in modular wall component1400 may be used to attach to additional componentry 1415 (such as asolar panel). The conduit line may be disposed such that the conduitline can be tied straight into a load center punch out, high enough thatan elbow could be fit, and routed through an exterior wall via aflexible gasket seal.

The example shown in FIG. 15 includes modular wall component 1500,adjacent wall 1505, adjacent ceiling 1510, additional componentry 1515,shower 1520, and sink 1525. Modular wall component 1500 is an exampleof, or includes aspects of, the corresponding element described withreference to FIGS. 1-14 . Adjacent wall 1505 is an example of, orincludes aspects of, the corresponding element described with referenceto FIGS. 12-14 . Adjacent ceiling 1510 is an example of, or includesaspects of, the corresponding element described with reference to FIGS.13-14 . Additional componentry 1515 is an example of, or includesaspects of, the corresponding element described with reference to FIG.14 .

Referring to FIG. 15 , finishing surfaces/components can be applied toone or more of modular wall component 1500, adjacent wall 1505, adjacentceiling 1510, and additional componentry 1515. For example, as shown inFIG. 15 , finishing surfaces are applied to modular wall component 1500,adjacent wall 1505, adjacent ceiling 1510, additional componentry 1515is enclosed in a cabinet, and shower 1520 and sink 1525 are installedand connected to one or more components of modular wall component 1500and additional componentry 1515 to supply plumbing service to shower1520 and sink 1525.

In some implementations, modular wall component 1500 can include afinish panel for an aesthetically pleasing appearance for an end-user.In an example, the finish panel may include one or more strips ofplywood. In some cases, the seams of the plywood (e.g., where the stripsof plywood abut against one another) may be located to be hidden byshelves and cabinets such that the end-user cannot see fasteners forattaching the plywood to modular wall component 1200. For example, theplywood strips may be located at a height from a specified lower datumto provide a solid structure for second finishing material to bemounted, such as drywall. As a result, in some cases, shelving andcabinets mounted to modular wall component 1500 provide a cleanappearance. Additionally or alternatively, a small undercut may be usedsuch that a bottom edge of a panel of modular wall component 1500 isreduced or eliminated during an alignment of a lower piece of modularwall component 1500 to the floor and an upper piece of modular wallcomponent 1500 to lower piece.

Panels may be set in such a way to mount a shower door and sides to ashower. Additionally, the panels around the shower may bepre-manufactured with cutouts for stub outs and temperature controlunits to be installed.

Manufacturing a Modular Wall Component

FIG. 16 shows an example of a method 1600 for providing a modular wallcomponent according to aspects of the present disclosure. In someexamples, the operations of FIG. 16 may be performed by a systemincluding a processor executing a set of codes to control functionalelements of an apparatus. Additionally or alternatively, certainprocesses are performed using special-purpose hardware. Generally, theoperations of FIG. 16 are performed according to the methods andprocesses described in accordance with aspects of the presentdisclosure. In some cases, the operations described herein are composedof various substeps, or are performed in conjunction with otheroperations.

Referring to FIG. 16 , in some cases, the system (such as a computersystem including one or more processors executing instructions stored ina memory) provides components that can be assembled to form a modularwall component (such as a modular wall component described withreference to FIGS. 1-15 ).

For example, in some cases, a user measures an installation site for themodular wall component and determines a location for the modular wallcomponent at the installation site. In some cases, the user determinesdimensions for the modular wall component based on the measurement ofthe installation site including a height in the first direction, a widthin the second direction, and a depth in the third direction describedwith reference to FIG. 1 .

In some cases, based on the dimensions for the installation site, theuser designs dimensions for a vertical panel and a horizontal panel asdescribed with reference to FIG. 1 (for example, using computer-aideddesign (CAD) software provided by the system on a user device). In somecases, the user designs an interior joint for the vertical panel and thehorizontal panel (for example, using the CAD software). In some cases,the user designs a location, shape, size, and orientation for at leastone feature to be included in the vertical panel or the horizontal panel(for example, using the CAD software). In some cases, the user designsthe feature based on a mechanical component, an electrical component, aplumbing component, or a combination thereof to be included in themodular wall component (for example, using the CAD software). In somecases, the user designs a mounting panel to be included in the modularwall component (for example, using the CAD software).

In some cases, the user creates a numerical control (NC) program basedon the design of the vertical panel, the horizontal panel, and thefeature (for example, using the system). In some cases, the user createsthe NC program based on the design of the mounting panel. In some cases,the user provides the NC program to a computer numerical control (CNC)machine included in the system.

At operation 1605, the system provides at least two vertical panels. Forexample, in some cases, the CNC machine cuts the at least two verticalpanels from sheet stock wood according to the NC program.

At operation 1610, the system provides at least two horizontal panels.For example, in some cases, the CNC machine cuts the at least twohorizontal panels from sheet stock wood according to the NC program.

In some cases, the system provides a mounting panel. For example, insome cases, the CNC machine cuts the mounting panel from sheet stockwood according to a mounting panel design included in the NC program.

At operation 1615, the system cuts at least two interior joints (orrespective portions of the at least two interior joints) in each of theat least two vertical panels and each of the at least two horizontalpanels. For example, in some cases, the CNC machine cuts portions fromthe at least two vertical panels and the at least two horizontal panelsto form the at least two interior joints (or the respective portions ofthe at least two interior joints) according to the NC program.

In some cases, the system cuts a mounting panel joint (or a respectiveportion of a mounting panel joint) from the vertical panel (or thehorizontal panel) and the mounting panel using the CNC machine accordingto a mounting panel joint design included in the NC program.

At operation 1620, the system cuts a feature from at least one of the atleast two vertical panels or the at least two horizontal panels. Forexample, in some cases, the CNC machine cuts the feature according tothe NC program. In some cases, the CNC machine cuts the feature from themounting panel.

At operation 1625, the at least two vertical panels and the at least twohorizontal panels are connected using the at least two interior jointsin each of the at least two vertical panels and the at least twohorizontal panels to form the modular wall component. For example, insome cases, a user or an assembly machine (such as a robot) operated byor included in the system joins the at least two vertical panels and theat least two horizontal panels using the at least two interior joints toform the modular wall component. In some cases, each edge of the atleast two horizontal panels forms an edge of a set of internalrectangular spaces defined by the at least two vertical panels. In somecases, the user or the assembly machine attaches the mounting panel tothe modular wall component via the mounting panel joint.

In some cases, a user or an assembly machine (such as a robot) operatedby or included in the system installs at least one of a mechanicalcomponent, an electrical component, and a plumbing component in themodular wall component such the mechanical component, the electricalcomponent, and/or the plumbing component is disposed in the feature.

In some cases, the modular wall component is provided to theinstallation site. In some cases, the modular wall component isinstalled at the installation site by a user or an assembly machine(such as a robot) operated by or included in the system. In some cases,a user or an assembly machine (such as a robot) operated by or includedin the system connects one or more external components to the modularwall component or an element of the modular wall component. In somecases, a user or an assembly machine (such as a robot) operated by orincluded in the system installs a finish material (e.g., drywall, tongueand groove paneling, etc.) on the modular wall component.

A method for providing a modular wall component including the secondlattice frame is described with reference to FIG. 17 .

FIG. 17 shows an example of a method 1700 for providing a modular wallcomponent including the second lattice frame according to aspects of thepresent disclosure. In some examples, the operations of FIG. 17 areperformed by a system including a processor executing a set of codes tocontrol functional elements of an apparatus. Additionally oralternatively, certain processes are performed using special-purposehardware. Generally, the operations of FIG. 17 are performed accordingto the methods and processes described in accordance with aspects of thepresent disclosure. In some cases, the operations described herein arecomposed of various substeps, or are performed in conjunction with otheroperations.

Referring to FIG. 17 , in some cases, the system (such as a computersystem including one or more processors executing instructions stored ina memory) provides components that can be assembled to form a modularwall component (such as a modular wall component described withreference to FIGS. 1-15 ) including two or more lattice frames.

For example, in some cases, a user measures an installation site for themodular wall component and determines a location for the modular wallcomponent at the installation site. In some cases, the user determinesdimensions for the modular wall component based on the measurement ofthe installation site including a height in the first direction, a widthin the second direction, and a depth in the third direction describedwith reference to FIG. 1 .

In some cases, based on the dimensions for the modular wall component,the user designs dimensions for a vertical panel and a horizontal panelfor a first lattice frame and an additional vertical panel and anadditional horizontal panel for a second lattice frame as described withreference to FIG. 1 (for example, using computer-aided design (CAD)software provided by the system on a user device). In some cases, theuser designs an interior joint for the vertical panel and the horizontalpanel (for example, using the CAD software) and an additional interiorjoint for the additional vertical panel and the additional horizontalpanel (for example, using the CAD software).

In some cases, the user designs the dimensions for the first latticeframe and second lattice frame according to a split in the modular wallcomponent as described with reference to FIG. 1 . In some cases, thesplit determines the design of the vertical panel, the horizontal panel,the additional vertical panel, and the additional horizontal panel. Insome cases, the location and/or the orientation of the split in themodular wall component is determined based on: a weight of the firstlattice frame and/or the second lattice frame; a location and/or numberof external components to be installed along with or attached to themodular wall component at the installation site; a geometry of theinstallation site such that each of the first lattice frame and thesecond lattice frame can be effectively and efficiently conveyed to theinstallation site (for example, so that the first lattice frame and thesecond lattice frame can be conveyed through a staircase, a doorway, acorner, etc. leading to the installation site); or a combinationthereof.

In some cases, the user designs a location, shape, size, and orientationfor at least one feature to be included in the vertical panel, thehorizontal panel, the additional vertical panel, or the additionalhorizontal panel (for example, using the CAD software). In some cases,the user designs the feature based on a mechanical component, anelectrical component, a plumbing component, or a combination thereof tobe included in the modular wall component (for example, using the CADsoftware).

In some cases, the user creates a numerical control (NC) program basedon the design of the first lattice frame and the second lattice frame.In some cases, the user provides the NC program to a computer numericalcontrol (CNC) machine included in the system.

At operation 1705, the at least two vertical panels and the at least twohorizontal panels are included in a lattice frame. For example, in somecases, the modular wall component formed by the system at operation 1625of FIG. 16 is implemented as the lattice frame.

At operation 1710, the system provides at least two additional verticalpanels. For example, in some cases, the CNC machine cuts the at leasttwo additional vertical panels from sheet stock wood according to the NCprogram.

At operation 1715, the system provides at least two additionalhorizontal panels. For example, in some cases, the CNC machine cuts theat least two additional horizontal panels from sheet stock woodaccording to the NC program.

At operation 1720, the system cuts at least two additional interiorjoints (or respective portions of the at least two interior joints) ineach of the at least two additional vertical panels and each of the atleast two additional horizontal panels. For example, in some cases, theCNC machine cuts portions from the at least two additional verticalpanels and the at least two additional horizontal panels to form the atleast two additional interior joints (or the respective portions of theat least two additional interior joints) according to the NC program.

At operation 1725, the at least two additional vertical panels and theat least two additional horizontal panels are connected using the atleast two additional interior joints in each of the at least twoadditional vertical panels and the at least two horizontal panels toform a second lattice frame. For example, in some cases, a user or anassembly machine (such as a robot) operated by or included in the systemassembles joins the at least two additional vertical panels and the atleast two additional horizontal panels using the at least two additionalinterior joints to form the second lattice frame. In some cases, eachedge of the at least two additional horizontal panels forms an edge of aset of additional internal rectangular spaces defined by the at leasttwo additional vertical panels. In some cases, the user or the assemblymachine attaches a mounting panel to the second lattice frame via amounting panel joint provided by the CNC machine.

At operation 1730, the first lattice frame and the second lattice frameare joined to form the modular wall component. For example, in somecases, a user or an assembly machine (such as a robot) operated by orincluded in the system joins the first lattice frame to the secondlattice frame using a joint cut into the first lattice frame and thesecond lattice frame, a bracket, a bolt, a screw, a magnet, adhesive,friction, or other attachment mechanism. In some cases, the firstlattice frame and the second lattice frame are joined to form themodular wall component at the installation site.

Accordingly, the present disclosure includes the following aspects.

A modular wall component is described. One or more aspects of themodular wall component include at least two vertical panels; at leasttwo horizontal panels configured to form a lattice frame together withthe at least two vertical panels, where each of the at least twohorizontal panels is connected to each of the at least two verticalpanels by an interior joint, respectively; and a feature configured tosecure a mechanical component, an electrical component, or a plumbingcomponent. In some aspects, the interior joint comprises a slot joint.

In some aspects, at least one vertical panel of the at least twovertical panels or at least one horizontal panel of the at least twohorizontal panels comprises a wood panel. In some aspects, the featurecomprises a slot, where a portion of the mechanical component, theelectrical component, or the plumbing component is disposed in the slot.

Some examples of the modular wall component include a mounting paneljoined to an external face of at least one of the at least two verticalpanels by a slot joint. Some examples of the modular wall componentfurther include an external structure mounted to the mounting panel at aload attachment point. Some examples of the modular wall componentfurther include a reinforcement component configured to reinforce theload attachment point.

Some examples of the modular wall component further include a secondlattice frame joined to the lattice frame and comprising at least twoadditional vertical panels and at least two additional horizontalpanels, where each of the at least two additional horizontal panels isconnected to each of the at least two additional vertical panels by anadditional interior joint, respectively. In some cases, a split betweenthe lattice frame and the second lattice frame is oriented based on ageometry of an external structure.

In some cases, a split between the lattice frame and the second latticeframe is oriented based on a geometry of the at least one of themechanical component, the electrical component, or the plumbingcomponent. In some cases, a split between the lattice frame and thesecond lattice frame is determined based on a weight of the latticeframe or a weight of the second lattice frame.

Some examples of the modular wall component further include a pluralityof features configured to accommodate an alignment of the mechanicalcomponent, the electrical component, or the plumbing component.

A modular wall component is described. One or more aspects of themodular wall component include at least two vertical panels; at leasttwo horizontal panels configured to form a lattice frame together withthe at least two vertical panels, where each of the at least twohorizontal panels forms an edge of a plurality of internal rectangularspaces defined by the at least two vertical panels; and a featureconfigured to secure a mechanical component, an electrical component, ora plumbing component.

Some examples of the modular wall component further include a mountingpanel joined to an external face of at least one of the at least twovertical panels. In some aspects, the mounting panel is joined to atleast one of the at least two horizontal panels. In some aspects, themounting panel is at least partially overlapped by at least one verticalpanel or at least one horizontal panel.

A method for manufacturing a modular wall component is described. One ormore aspects of the method include providing at least two verticalpanels; providing at least two horizontal panels; cutting at least twointerior joints in each of the at least two vertical panels and each ofthe at least two horizontal panels; cutting a feature from the at leasttwo vertical panels or the at least two horizontal panels; andconnecting the at least two vertical panels and the at least twohorizontal panels using the at least two interior joints in each of theat least two vertical panels and the at least two horizontal panels toform the modular wall component.

Some examples of the method further include including the at least twovertical panels and the at least two horizontal panels in a firstlattice frame. Some examples further include providing at least twoadditional vertical panels. Some examples further include providing atleast two additional horizontal panels. Some examples further includecutting at least two additional interior joints in each of the at leasttwo additional vertical panels and each of the at least two additionalhorizontal panels. Some examples further include connecting the at leasttwo additional vertical panels and the at least two additionalhorizontal panels using the at least two additional interior joints ineach of the at least two additional vertical panels and the at least twohorizontal panels to form a second lattice frame. Some examples furtherinclude joining the first lattice frame and the second lattice frame toform the modular wall component.

Some examples of the method further include determining a split betweenthe lattice frame and the second lattice frame, where the at least twovertical panels, the at least two horizontal panels, the at least twoadditional vertical panels, the at least two additional horizontalpanels, or a combination thereof are provided based on the split.

Some examples of the method further include determining the split basedon a mechanical component, an electrical component, a plumbingcomponent, an appliance, a geometry of an external structure, adimension of the lattice frame, a dimension of the second lattice frame,or a combination thereof.

The description and drawings described herein represent exampleconfigurations and do not represent all the implementations within thescope of the claims. For example, the operations and steps may berearranged, combined, or otherwise modified. Also, structures anddevices may be represented in the form of block diagrams to representthe relationship between components and avoid obscuring the describedconcepts. Similar components or features may have the same name but mayhave different reference numbers corresponding to different figures.

Some modifications to the disclosure may be readily apparent to thoseskilled in the art, and the principles defined herein may be applied toother variations without departing from the scope of the disclosure.Thus, the disclosure is not limited to the examples and designsdescribed herein, but is to be accorded the broadest scope consistentwith the principles and novel features disclosed herein.

The described methods may be implemented or performed by devices thatinclude a general-purpose processor, a digital signal processor (DSP),an application specific integrated circuit (ASIC), a field programmablegate array (FPGA) or other programmable logic device, discrete gate ortransistor logic, discrete hardware components, or any combinationthereof. A general-purpose processor may be a microprocessor, aconventional processor, controller, microcontroller, or state machine. Aprocessor may also be implemented as a combination of computing devices(e.g., a combination of a DSP and a microprocessor, multiplemicroprocessors, one or more microprocessors in conjunction with a DSPcore, or any other such configuration). Thus, the functions describedherein may be implemented in hardware or software and may be executed bya processor, firmware, or any combination thereof. If implemented insoftware executed by a processor, the functions may be stored in theform of instructions or code on a computer-readable medium.

Computer-readable media includes both non-transitory computer storagemedia and communication media including any medium that facilitatestransfer of code or data. A non-transitory storage medium may be anyavailable medium that can be accessed by a computer. For example,non-transitory computer-readable media can comprise random access memory(RAM), read-only memory (ROM), electrically erasable programmableread-only memory (EEPROM), compact disk (CD) or other optical diskstorage, magnetic disk storage, or any other non-transitory medium forcarrying or storing data or code.

Also, connecting components may be properly termed computer-readablemedia. For example, if code or data is transmitted from a website,server, or other remote source using a coaxial cable, fiber optic cable,twisted pair, digital subscriber line (DSL), or wireless technology suchas infrared, radio, or microwave signals, then the coaxial cable, fiberoptic cable, twisted pair, DSL, or wireless technology are included inthe definition of medium. Combinations of media are also included withinthe scope of computer-readable media.

In this disclosure and the following claims, the word “or” indicates aninclusive list such that, for example, the list of X, Y, or Z means X orY or Z or XY or XZ or YZ or XYZ. Also the phrase “based on” is not usedto represent a closed set of conditions. For example, a step that isdescribed as “based on condition A” may be based on both condition A andcondition B. In other words, the phrase “based on” shall be construed tomean “based at least in part on.” Also, the words “a” or “an” indicate“at least one.”

What is claimed is:
 1. A modular wall component, comprising: at leasttwo vertical panels; at least two horizontal panels configured to form alattice frame together with the at least two vertical panels, whereineach of the at least two horizontal panels is connected to each of theat least two vertical panels by an interior joint, respectively; and afeature configured to secure a mechanical component, an electricalcomponent, or a plumbing component.
 2. The modular wall component ofclaim 1, wherein: at least one vertical panel of the at least twovertical panels or at least one horizontal panel of the at least twohorizontal panels comprises a wood panel.
 3. The modular wall componentof claim 1, wherein: the feature comprises a slot, wherein a portion ofthe mechanical component, the electrical component, or the plumbingcomponent is disposed in the slot.
 4. The modular wall component ofclaim 1, further comprising: a mounting panel joined to an external faceof at least one of the at least two vertical panels by a slot joint. 5.The modular wall component of claim 4, further comprising: an externalstructure mounted to the mounting panel at a load attachment point. 6.The modular wall component of claim 5, further comprising: areinforcement component configured to reinforce the load attachmentpoint.
 7. The modular wall component of claim 1, wherein: the interiorjoint comprises a slot joint.
 8. The modular wall component of claim 1,further comprising: a second lattice frame joined to the lattice frameand comprising at least two additional vertical panels and at least twoadditional horizontal panels, wherein each of the at least twoadditional horizontal panels is connected to each of the at least twoadditional vertical panels by an additional interior joint,respectively.
 9. The modular wall component of claim 8, wherein: a splitbetween the lattice frame and the second lattice frame is oriented basedon a geometry of an external structure.
 10. The modular wall componentof claim 8, wherein: a split between the lattice frame and the secondlattice frame is oriented based on a geometry of the mechanicalcomponent, the electrical component, or the plumbing component.
 11. Themodular wall component of claim 8, wherein: a split between the latticeframe and the second lattice frame is determined based on a weight ofthe lattice frame or a weight of the second lattice frame.
 12. Themodular wall component of claim 1, further comprising: a plurality offeatures configured to accommodate an alignment of the mechanicalcomponent, the electrical component, or the plumbing component.
 13. Amodular wall component, comprising: at least two vertical panels; atleast two horizontal panels configured to form a lattice frame togetherwith the at least two vertical panels, wherein each of the at least twohorizontal panels forms an edge of a plurality of internal rectangularspaces defined by the at least two vertical panels; and a featureconfigured to secure a mechanical component, an electrical component, ora plumbing component.
 14. The modular wall component of claim 13,further comprising: a mounting panel joined to an external face of atleast one of the at least two vertical panels.
 15. The modular wallcomponent of claim 14, wherein: the mounting panel is joined to at leastone of the at least two horizontal panels.
 16. The modular wallcomponent of claim 14, wherein: the mounting panel is at least partiallyoverlapped by at least one vertical panel or at least one horizontalpanel.
 17. A method for manufacturing a modular wall component,comprising: providing at least two vertical panels; providing at leasttwo horizontal panels; cutting at least two interior joints in each ofthe at least two vertical panels and each of the at least two horizontalpanels; cutting a feature from the at least two vertical panels or theat least two horizontal panels; and connecting the at least two verticalpanels and the at least two horizontal panels using the at least twointerior joints in each of the at least two vertical panels and the atleast two horizontal panels to form the modular wall component.
 18. Themethod of claim 17, further comprising: including the at least twovertical panels and the at least two horizontal panels in a firstlattice frame; providing at least two additional vertical panels;providing at least two additional horizontal panels; cutting at leasttwo additional interior joints in each of the at least two additionalvertical panels and each of the at least two additional horizontalpanels; connecting the at least two additional vertical panels and theat least two additional horizontal panels using the at least twoadditional interior joints in each of the at least two additionalvertical panels and the at least two horizontal panels to form a secondlattice frame; and joining the first lattice frame and the secondlattice frame to form the modular wall component.
 19. The method ofclaim 18, further comprising: determining a split between the firstlattice frame and the second lattice frame, wherein the at least twovertical panels, the at least two horizontal panels, the at least twoadditional vertical panels, the at least two additional horizontalpanels, or a combination thereof are provided based on the split. 20.The method of claim 19, further comprising: determining the split basedon a mechanical component, an electrical component, a plumbingcomponent, an appliance, a geometry of an external structure, adimension of the first lattice frame, a dimension of the second latticeframe, or a combination thereof.